length MERCEDES-BENZ SPRINTER 2006 User Guide

WIPER ARM
DESCRIPTION
The wiper arms are the rigid members located
between the wiper pivots that protrude from the cowl
top panel near the base of the windshield and the
wiper blades on the windshield glass (Fig. 23). These
wiper arms feature an over-center hinge that allows
easy access to the windshield glass for cleaning. The
wiper arm has a die cast metal pivot end with a
large tapered mounting hole at one end. A removable
molded black plastic pivot cover fits loosely over and
pivots on the wiper arm hinge pin, then snaps over
the pivot end to conceal the wiper arm retaining nut.
The wide end of a tapered, stamped steel channel
hinges on and is secured with a hinge pin to the
pivot end of the wiper arm. One end of a long, rigid,
stamped steel strap, with a small hole near its pivot
end, is riveted and crimped within the narrow end of
the stamped steel channel. The tip of the wiper blade
end of this strap is bent back under itself to form a
small hook. Concealed within the stamped steel
channel, one end of a long spring is engaged with awire hook on the underside of the die cast pivot end,
while the other end of the spring is hooked through
the small hole in the steel strap. The entire wiper
arm has a satin black finish applied to all of its vis-
ible surfaces.
Near the hook of the wiper arm steel strap is a
locating hole for the washer nozzle that is mounted
on the wiper arm. A U-shaped molded plastic guard
snaps onto the underside of the strap to conceal and
protect the washer nozzle hose. There are also two
small molded plastic washer nozzle hose routing
brackets clipped onto the underside of the wiper arm
pivot end.
The wiper arms for this model are unequal in
length, with the longer arm being installed on the
left (driver) side of the windshield. A wiper arm can-
not be adjusted or repaired. If damaged or faulty, the
entire wiper arm unit must be replaced. The washer
nozzle, nozzle hose, routing brackets, and pivot end
Fig. 23 Wiper Arm
1 - HOOK 7 - CHANNEL
2 - STRAP 8 - COVER
3 - WASHER HOSE 9 - PIVOT END
4 - BRACKET (2) 10 - GUARD
5 - HINGE PIN 11 - WASHER NOZZLE
6 - TENSION SPRING
VAWIPERS/WASHERS 8R - 23

cover are available for individual service replace-
ment.
OPERATION
The wiper arms are designed to mechanically
transmit the motion from the wiper pivots to the
wiper blades. The wiper arm must be properly
indexed to the wiper pivot in order to maintain the
proper wiper blade travel on the glass. The tapered
mounting hole in the wiper arm pivot end interlocks
with the serrations on the outer circumference of the
wiper pivot shaft, allowing positive engagement and
finite adjustment of this connection. The mounting
nut locks the wiper arm to the threaded end of the
wiper pivot shaft. The spring-loaded wiper arm hinge
controls the down-force applied through the tip of the
wiper arm to the wiper blade on the glass. The hook
formation on the tip of the wiper arm provides a cra-
dle for securing and latching the wiper blade pivot
block to the wiper arm.
REMOVAL
(1) Disconnect the washer nozzle hose from the
elbow fitting on the cowl top panel near the pivot end
of the wiper arm (Fig. 24).
CAUTION: The use of a screwdriver or other prying
tool to remove a wiper arm may distort it. This dis-
tortion could allow the arm to come off of the wiper
pivot during wiper operation, regardless of how
carefully it is reinstalled.
(2) Unsnap the end of the pivot cover from the
wiper blade pivot end, then pull the cover away from
the wiper arm hinge pin to remove the cover from
the wiper blade.(3) Remove the nut that secures the wiper arm to
the wiper pivot shaft.
(4) If necessary, use a suitable battery terminal
puller to disengage the wiper arm from the wiper
pivot shaft (Fig. 25).
(5) Remove the wiper arm pivot end from the
wiper pivot shaft.
INSTALLATION
NOTE: Be certain that the wiper motor is in the park
position before attempting to install the wiper arms.
Turn the ignition switch to the On position and
move the right (wiper) control stalk of the multi-
function switch to its Off position. If the wiper piv-
ots move, wait until they stop moving, then turn the
ignition switch back to the Off position. The wiper
motor is now in its park position.
NOTE: The wiper arms and wiper blades for this
model are both unequal in length, with the longer
arm and blade being installed on the left (driver)
side of the windshield.
(1) The wiper arms must be indexed to the wiper
pivot shafts with the wiper motor in the park posi-
tion to be properly installed. Position the wiper arm
pivot ends onto the wiper pivots so that the lower
edge of the wiper arm tip is aligned with the black
wiper alignment line located near the lower edge of
the windshield glass (Fig. 24).
(2) Once the wiper blade is aligned, lift the wiper
arm away from the windshield slightly to relieve the
spring tension on the pivot end and push the pivot
hole in the pivot end of the arm down firmly and
evenly over the wiper pivot shaft. Gently lower the
wiper arm until the wiper blade rests on the glass.
Fig. 24 Wiper Arm Remove/Install
1 - PIVOT COVER
2 - NUT
3 - PIVOT SHAFT
4 - WASHER NOZZLE HOSE
5 - ELBOW FITTING
6 - WIPER ARM
Fig. 25 Wiper Arm Puller - Typical
1 - WIPER ARM
2 - WIPER PIVOT SHAFT
3 - BATTERY TERMINAL PULLER
8R - 24 WIPERS/WASHERSVA

WIPER BLADE
DESCRIPTION
Each wiper blade is secured by an integral latching
pivot block to the hook formation on the tip of the
wiper arm, and rests on the glass near the base of
the windshield when the wipers are not in operation
(Fig. 26). The wiper blade consists of the following
components:
²Superstructure- The superstructure includes
several stamped steel bridges and links with claw
formations that grip the wiper blade element. Also
included in this unit is the latching, molded plastic
pivot block that secures the superstructure to the
wiper arm. All of the metal components of the wiper
blade have a satin black finish applied.
²Element- The wiper element or squeegee is the
resilient rubber member of the wiper blade that con-
tacts the glass.
²Flexor- The flexor is a rigid metal component
running along the length of the wiper element on
each side, where it is gripped by the claws of the
superstructure.
All Sprinter models have unequal length wiper
blades with non-replaceable rubber elements (squee-
gees). The left (driver) side wiper blade is 60.0 centi-
meters (23.5 inches), and the right (passenger) side
wiper blade is 55.0 centimeter (21.5 inches). These
wiper blades also include an anti-lift feature. The
wiper blades cannot be adjusted or repaired. If faulty,
worn, or damaged the entire wiper blade unit must
be replaced.
OPERATION
The wiper blades are moved back and forth across
the glass by the wiper arms when the wipers are
being operated. The wiper blade superstructure isthe flexible frame that grips the wiper blade element
and evenly distributes the force of the spring-loaded
wiper arm along the length of the element. The com-
bination of the wiper arm force and the flexibility of
the superstructure makes the element conform to
and maintain proper contact with the glass, even as
the blade is moved over the varied curvature that
may be encountered across the glass surface. The
wiper element flexor provides the claws of the blade
superstructure with a rigid, yet flexible component
on the element which can be gripped. The rubber ele-
ment is designed to be stiff enough to maintain an
even cleaning edge as it is drawn across the glass,
but resilient enough to conform to the glass surface
and flip from one cleaning edge to the other each
time the wiper blade changes directions.
REMOVAL
NOTE: The wiper arms and wiper blades for this
model are both unequal in length, with the longer
arm and blade being installed on the left (driver)
side of the windshield.
(1) Turn the wiper control knob on the end of the
multi-function switch control stalk to the On posi-
tion. Cycle the wiper blades to a convenient working
location on the windshield by turning the ignition
switch to the On and Off positions.
(2) Lift the wiper arm to raise the wiper blade and
element off of the glass, until the wiper arm hinge is
in its over-center position.
(3) To remove the wiper blade from the wiper arm,
depress the pivot block latch release tab under the
tip of the arm and slide the blade away from the tip
Fig. 26 Wiper Blade
1 - PIVOT BLOCK 4 - FLEXOR
2 - SUPERSTRUCTURE 5 - ELEMENT
3 - CLAWS 6 - PIVOT PIN
8R - 26 WIPERS/WASHERSVA

towards the pivot end of the arm far enough to dis-
engage the pivot block from the hook formation on
the end of the arm (Fig. 27).
(4) Extract the hook formation on the tip of the
wiper arm from the opening in the wiper blade
superstructure ahead of the wiper blade pivot block/
latch unit.
CAUTION: Do not allow the wiper arm to spring
back against the glass without the wiper blade in
place or the glass may be damaged.
(5) Gently lower the wiper arm tip onto the glass.
INSTALLATION
NOTE: The wiper arms and wiper blades for this
model are both unequal in length, with the longer
arm and blade being installed on the left (driver)
side of the windshield.
(1) Lift the wiper arm off of the windshield glass,
until the wiper arm hinge is in its over-center posi-
tion.
(2) Position the wiper blade near the hook forma-
tion on the tip of the arm.
(3) Insert the hook formation on the tip of the
wiper arm through the opening in the wiper blade
superstructure ahead of the wiper blade pivot block/
latch unit far enough to engage the pivot block with
the hook (Fig. 27).
(4) Slide the wiper blade pivot block/latch up into
the hook formation on the tip of the wiper arm until
the latch release tab snaps into its locked position.
Latch engagement will be accompanied by an audible
click.
(5) Gently lower the wiper blade onto the glass.
Fig. 27 Wiper Blade Remove/Install
1 - HOOK
2 - WIPER BLADE
3 - WIPER ARM
4 - RELEASE TAB
VAWIPERS/WASHERS 8R - 27

TERMINAL
REMOVAL
(1) Follow steps for removing terminals described
in the connector removal section.
(2) Cut the wire 6 inches from the back of the con-
nector.
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove one±half (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure) .
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 1±1/2
inches behind the connector and 2 inches past the
repair.
(7) Connect battery and test all affected systems.
WIRE
STANDARD PROCEDURE
WIRE SPLICING
When splicing a wire, it is important that the cor-
rect gage be used as shown in the wiring diagrams.
(1) Remove one-half (1/2) inch of insulation from
each wire that needs to be spliced.
(2) Place a piece of adhesive lined heat shrink tub-
ing on one side of the wire. Make sure the tubing will
be long enough to cover and seal the entire repair
area.
(3) Place the strands of wire overlapping each
other inside of the splice clip (Fig. 12).(4) Using crimping tool, Mopar p/n 05019912AA,
crimp the splice clip and wires together (Fig. 13).
(5) Solder the connection together using rosin core
type solder only (Fig. 14).
CAUTION: DO NOT USE ACID CORE SOLDER.
(6) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing (Fig. 15).
Fig. 12 1 SPLICE BAND
1 - SPLICE BAND
Fig. 13 2 CRIMPING TOOL
1 - CRIMPING TOOL
Fig. 14 3 SOLDER SPLICE
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
Fig. 15 4 HEAT SHRINK TUBE
1 - SEALANT
2 - HEAT SHRINK TUBE
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATIONVA

(8) Remove bottom portion of the air cleaner hous-
ing out of the rubber bushings in the inner fender
and remove (Fig. 11).
INSTALLATION
NOTE: Ensure that the seal between the inner
fender well and the air intake hose is correctly
installed.
(1) Seat and retain bottom portion of the air
cleaner housing into the bushings on the inner
fender (Fig. 11).
(2) Install the air intake hose to the air cleaner
housing the align and install it in the inner fender
and wheel housing liner (Fig. 11).
(3) Install air cleaner element (Fig. 11).
(4) Install and clip air cleaner top to air cleaner
body and connect the air intake pressure sensor (Fig.
11).
(5) Install air flow sensor (Fig. 11).
(6) Install heat shield.
(7) Connect negative battery cable.
CYLINDER HEAD
DESCRIPTION
The cylinder head is made of high temperature
resistant aluminum alloy and features optimized spi-ral swirl intake ducts and a separate camshaft hous-
ing made of die cast aluminum. The combustion
chamber features four valves per cylinder, central
injectors and glow plugs arranged slant wise. The
intake and exhaust valves have solid valve stems and
conical valve springs. The cylinder head is not ser-
viceable and must be replaced should a repair
become necessary.
STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER HEAD
BOLT INSPECTION
(1) Measure cylinder head bolts between points
shown (Fig. 12).
Cylinder Head
BoltsThread Diame-
ter12 M
Length When
New102 mm
Maximum
Length104 mm
(2) If the cylinder head bolt length is greater than
the maximum allowable measurement, replace the
cylinder head bolts.
STANDARD PROCEDURE - MEASURE CYLIN-
DER HEAD SURFACE
NOTE: DO NOT machine the cylinder head surface.
(1) Disconnect negative battery cable.
(2) Remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(3) Remove valves.
(4) Inspect cylinder head contact surface for flat-
ness, porous and damage.
(5) Using a straight edge, measure cylinder head
and cylinder block flatness.
(6) Measure cylinder head height at point (1) indi-
cated and retain reading (Fig. 13).
Fig. 11 AIR CLEANER HOUSING
1 - AIR FLOW SENSOR
2 - GASKET
3 - AIR INTAKE HOSE
4 - AIR CLEANER HOUSING
5 - AIR CLEANER ELEMENT
6 - AIR INTAKE PRESSURE SENSOR
7 - AIR CLEANER HOUSING COVER
Fig. 12 Measuring Cylinder Head Bolts
9 - 22 ENGINEVA

Distance between middle
connecting rod bore to
connecting rod bushing
bore148.970 mm to 149.030
mm
Allowable out-of-round-
ness and taper of basic
bore.020 mm
Allowable twist of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.100 mm
Allowable variation of
axial parallelism of con-
necting rod bearing bore
to connecting rod bush-
ing bore over a length of
100 mm.045 mm
Allowable difference in
weight of complete con-
necting rod of an engine2g
Connecting rod inner
bushing30.018 to 30.024 mm
Connecting rod outer
bushing32.575 mm to 32.600
mm
Connecting rod basic
bore32.500 mm to 32.525
mm
Piston pin play in con-
necting rod.018 mm to.024 mm
Peak-to-Valley height
(Rz) of connecting rod
bushing on inside5
Connecting rod bolt
threadM8x1
STANDARD PROCEDURE - MEASURING PIS-
TON PROTRUSION
After replacing the pistons/connecting rods or
machining the engine block contact surface, it is then
necessary to measure the piston protrusion.
Measure protrusion between piston crown and cyl-
inder head contact surface without the head gasket
installed. The measurment must be carried out in
the direction of the piston pin in order to eliminate
piston rock.
(1) Measure piston protrusion at the two measur-
ing points (arrows) (Fig. 39).
Piston protrusion with new crankcase should be
0.38 - 0.62 mm.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Remove the engine (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove the cylinder head (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
(4) Remove the oil pan (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(5) Push back on the chain tensioner and remove
the oil pump chain from the oil pump.
(6) Remove the oil pump.
NOTE: Mark the connecting rod and connecting rod
bearing cap to each other at the inlet side.
(7) Remove the connecting rod bearing cap.
NOTE: Do Not mix up the top and bottom connect-
ing rod bearing shells.
(8) Mark the connecting rod bearing shell and the
connecting rod bearing cap to each other.
Fig. 39 MEASURING PISTON PROTRUSION
1 - PISTON PROTRUSION MEASUREMENT
VAENGINE 9 - 47

INSTALLATION
NOTE: Oil pan bolts are of different diameters and
lengths. Care must be take to install the bolts in
their original position (Fig. 59).
NOTE: Clean the strainer of the oil pump. If the oil
pump is dry, coat the inside with clean engine oil.
NOTE: Thoroughly clean all mating surfaces with
the appropriate solvents to assure that no grease or
oil is present during reassembly.
(1) Slide the oil pan into position.
(2) Slide the gasket into position.
(3) Add sealant to the joints on the engine block
where indicated (Fig. 58).
Fig. 57 OIL PAN
1 - O-RING 6 - CONNECTOR FOR OIL LEVEL SENSOR
2 - OIL PUMP 7 - OIL PAN
3 - GASKET 8 - TRANSMISSION LINE
4 - WIRING HARNESS DUCT 9 - OIL PUMP CHAIN
5 - TRANSMISSION LINE 10 - OIL PUMP CHAIN TENSIONER
Fig. 58 OIL PAN GASKET
9 - 60 ENGINEVA

(8) Position the front exhaust pipe aside.
(9) Lower the vehicle.
(10) Remove the air cleaner housing hose from the
turbocharger and position aside (Fig. 71).
(11) Remove the turbocharger oil cooler lines (Fig.
72).(12) Remove the turbocharger to exhaust manifold
fasteners and remove turbocharger (Fig. 72).
(13) Remove the self locking exhaust manifold fas-
teners (Fig. 72).
(14) Remove exhaust manifold and clean mating
surface.
INSTALLATION
NOTE: Exhaust manifold surface must be flat within
0.006 in. per foot (0.15mm per 300mm) of manifold
length.
(1) Inspect exhaust manifold gasket surface for
flatness with a straight edge.
(2) Inspect exhaust manifold for cracks or distor-
tion.
(3) Install new exhaust manifold gasket over the
studs.
(4) Position the exhaust manifold over to studs
and tighten retaining nuts to 30 N´m (22 lbs.ft.).
NOTE: Replace the turbocharger oil cooler line
banjo bolt seals before installing the oil cooler line.
(5) Install turbocharger (Refer to 11 - EXHAUST
SYSTEM/TURBOCHARGER SYSTEM/TURBO-
CHARGER - INSTALLATION).
(6) Raise and support the vehicle.
(7) Install the front exhaust pipe to turbocharger
(Fig. 71).
Fig. 71 TURBOCHARGER
1 - EXHAUST MANIFOLD
2 - HEATER PIPE
3 - AIR INLET TUBE
4 - TURBOCHARGER
5 - AIR CLEANER HOUSING
6 - EXHAUST CLAMP
7 - FRONT EXHAUST PIPE
Fig. 72 EXHAUST MANIFOLD
1 - CYLINDER HEAD
2 - TURBOCHARGER OIL COOLER LINE
3 - TIMING CHAIN TENSIONER
4 - BANJO BOLT
5 - EXHAUST MANIFOLD
VAENGINE 9 - 69

INSTALLATION
(1) Position the MAF sensor to air cleaner housing
and install the retaining screws (Fig. 24).
(2) Connect the air intake hose to the MAF sensor
and tighten clamp.
(3) connect the MAF wiring harness connector.
(4) Connect negative battery cable.
O2 SENSOR
DESCRIPTION
The wide band oxygen sensor measures the oxygen
content in the exhaust gas to monitor EGR. The sen-
sor is mounted in the exhaust pipe at a 30 degree
angle to prevent the collection of moisture between
the sensor housing and element. The sensor is
located close to the turbocharger for a quicker
response time.
The oxygen sensor has five wires (heater power
and ground, reference voltage, and 2 wires for a
pump cell). The oxygen sensor connects to a six wire
harness connector. A non serviceable trimming resis-
tor is built into the sensor connector. The resistance
is dependent on the over all length and type of sen-
sor.
OPERATION
The O2 sensor is a planar zirconium dioxide (ZrO2)
dual cell limiting current probe with a integralheater. The term wide ban, refers to the ability of the
O2 sensor to generate a clear signal over a wide air-
fuel ratio measuring range. As a dual sensor, it incor-
porates a second O2 chamber (oxygen pump cell),
which requires a separate voltage supply.
The sensor element combines a sensor cell (8) and
an oxygen pump cell (9). Both cells are made of zir-
conium-dioxide (ZrO2) and are coated with porous
platinum electrodes. The sensor cell operates just
like a typical O2 sensor. The oxygen pump cell trans-
port oxygen ions when voltage is applied.
A gas sample chamber (5) is sandwiched between
the oxygen pump cell and the sensor cell. A pump
electrode and sensor cell electrode are located in the
sample chamber. A sample passage (10) connects the
sample chamber to the surrounding exhaust gas. A
sensor cell electrode is located in the reference air
channel (6), which connects to the outside air (Fig.
25).
Fig. 24 MANIFOLD AIR FLOW SENSOR
1 - WIRING HARNESS
2 - AIR INTAKE HOSE
3 - CLAMP
4 - MAF SENSOR
5 - AIR CLEANER HOUSING
VAFUEL INJECTION 14 - 45